Dynamic flange seal and sealing system

ABSTRACT

The present invention features a flange to flange dynamic seal and sealing system, particularly suited for use within high temperature, high pressure environments, such as a delayed coking process. The dynamic flange seal and sealing system comprises two primary elements or seals, each of which are capable of independently forming a flange seal between two flanged components or combining to create a flange seal. Specifically, these primary seals are an iconel bellows seal and a bi-material gasket, each of which surround a flange opening along a sealing surface. The flange seal created by the dynamic flange seal and sealing system is capable of being maintained in light of, or rather the sealing system adapts to, any structural or environmental changes within the connected flanges. As such, the flange seal may be a dynamic flange seal or a static flange seal or both.

RELATED APPLICATIONS

This application claims priority to U.S. patent application Ser. No.09/946,917, entitled COKE DRUM BOTTOM DE-HEADING SYSTEM, filed Sep. 5,2001, listing the same inventor as the application.

BACKGROUND

1. Field of the Invention

The present invention relates to seals and dynamic sealing systems forsealing one or more connected flanges together, or generally a dynamicflange seal and sealing system for flanged components. The presentinvention more particularly relates to a dynamic flange seal and sealingsystem capable of forming a dynamic flange seal capable of adjustingwith various structural or environmental changes in order to maintainthe integrity of the seal existing between two or more connectedflanges.

2. Background of the Invention and Related Art

In virtually every conduit or pipe installation where moderate to highpressures and temperatures exist, a problem is encountered when it comesto flange design and usage. Most problems either reside in the actualconnection itself, the means used to connect the flanges together, orthe seal existing and desired there between. There are presently manyflanged components or structures on the market which are attached toother components, pipes, conduits, or the like. The relative size andcomplexity of these flanges varies with the size of the neededcomponents.

In many high pressure, high temperature systems, seals are used tomaintain the pressure in the system. Almost all prior art seals use agasket between the coupled flanged components. Most of these seals usethe force required to secure the flanged components together to alsocreate the seal. This requires many connections to apply enough forceover a wide area to eliminate gaps in the seal.

Many gaskets used to provide a seal between connected flanged componentsare made of an elastic material like rubber, since elastic gaskets canbe reused. However, elastic materials, while useful in many settings,are not suited for high pressure, high temperature environments forobvious reasons. Indeed, elastic gaskets typically are utilized only insettings where the temperature is kept below 250 degrees F. In addition,elastic gaskets tend to wear out relatively quickly, especially whensubject to extreme conditions. Any degradation of the seal existingbetween connected flanged components usually means that the system willexperience leaks and other failures. For these reasons, elastic gasketsare less than desirable for use in many settings.

Several other settings call for less-elastic, metallic gaskets, sincethey have many advantages over their elastic counterparts. Metallicgaskets can be used in many extreme environments where highertemperatures and pressures exist. However, because metallic gaskets areless elastic, they cannot generally be reused. Moreover, metallicgaskets are subject to leaks caused by various stresses (and stressrelief) and creep.

A few special seals are designed to prevent leaks due to creep andrepeated stress. For instance, a Batzer flange, commonly known in theprior art, provides sufficient elastic deflection and seal force tomaintain a seal when creep and relief stresses are present. Batzerflanges have a slightly conical flange. The slight deflection in theflange making the conical shape provides the elastic deflection.However, a problem with the Batzer seal is that as the size of the sealincreases the flange size must also increase. As such, large sealsrequire abnormally and oftentimes prohibitively large flanges. Also theseal is typically positioned along an edge, which makes the seal morevulnerable to corrosion or damage.

SUMMARY AND OBJECTS OF THE INVENTION

In light of the deficiencies in the prior art, the present inventionseeks to improve flange to flange connections by providing a seal thataccounts for cyclical variations of temperature and pressure betweenflanged components.

Therefore, it is an object of some embodiments of the present inventionto provide a flexible or dynamic flange seal and sealing system thatprovides an improved seal between flanged components.

It is another object of some embodiments of the present invention toprovide a dynamic flange seal and sealing system that can withstand hightemperature, high pressure environments by adjusting to structuraland/or environmental changes often experienced in an extremeenvironment.

It is still another object of some embodiments of the present inventionto provide a dynamic flange seal and sealing system that may be usedwithin new components, but that is also capable of being retro-fit intoexisting components, such as on-site modifying of flanged components tosupport the dynamic flange seal and sealing system as taught herein.

Other objects not specifically recited herein will be apparent to one ofordinary skill in the art. As such, these are not meant to be limitingin any way.

In accordance with the invention as embodied and broadly describedherein, the present invention features a flange to flange dynamic sealand sealing system. There are two primary elements or seals featured inthis system, or rather, the system comprises two primary seals, each ofwhich are capable of independently forming a flange seal between twoflanged components. Specifically, these primary seals are an iconelbellows seal and a bi-material seal, each of which surround a flangeopening along a sealing surface either in whole or in segments. Asstated, each of these elements are independent of one another and formindependent seals. However, these elements may also be combined, or usedin conjunction with one another, to create a redundant flange seal. Inaddition, the flange seal created by the dynamic flange seal and sealingsystem is capable of being maintained in light of, or rather the dynamicsealing system adapts to, any structural or environmental changesbetween the connected flanges.

In one exemplary embodiment of the seal system, two iconel bellow sealsare contained and supported within a recess formed in a first flange ofa first component or member, wherein the iconel bellows seals areseparated by a seal stainless steel annular spacer. The iconel bellowsseal functions to provide a biased, dynamic seal by allowing for andproviding adjustments within the seal as dictated by the existingconditions experienced between the flanges. Stated another way, theiconel bellows seal is capable of expanding to maintain a seal even whenthe flanged components separate slightly from each other, to maintainthe integrity of the seal.

The iconel bellows seal comprises a corrugated stainless steel ribbonwhich is compressed between two flanged elements, and is seated in arecess between the flanges.

Preferably, the iconel bellows seal provides even further sealing byapplying a silver seal to the milled recess in the flanges before andafter inserting the bellows seals and spacers. The silver seal or othersealant may be omitted at the location where the inner bellows sealcontacts the flange joint near the interior of the drum. This allows asmall amount of steam to flow under pressure behind the blows seal andto the drum to pressurize the passage to contamination from coke fromthe contacting the down seal and to assist in monitoring the states ofthe seal. Of course, if necessary or desired, the iconel bellows sealcould be sealed entirely so as to allow no fluid transfer therethrough.Likewise, the iconel bellows seal could be secured within the flangeusing no seals. In a semi-sealed configuration, the fluid flow ispreferably specifically controlled using various means, such as via asteam inlet and purge system and associated control and monitoringmodule.

As stated, the dynamic flange seal and sealing system further featuresor comprises a seal in the form of a bi-material gasket. In oneexemplary embodiment, the bi-material gasket is supported within a firstflange and is preferably positioned adjacent an iconel bellows seal. Thebi-material may also be a stand alone seal. The bi-material gasketpreferably comprises a flexor and a flexible sealant adjacent to theflexor that displaces in response to any flexing or contracting of theflexor. The flexor is caused to contract as the first flange and asecond flange are coupled together, and as means for coupling andsecuring the two components together is actuated (e.g. bolts tightened,latches latched, etc.). The connection and subsequent securing of thetwo flanges together forces the flexor to contract. This contractionresultantly causes the flexible sealant attached thereto to displace andseal against the sealing surfaces of the two connected flanges. Thegreater the compression between the flanges, the more the flexiblesealant is forced to displace and the tighter, more secure the sealbetween the flanges. This concept is referred to herein as the flexfactor of the flexor and is relative to the amount of force exerted uponor applied to the flexor as a result of the pressure within orcompression between the connected flanges. Together or separate, theiconel bellows seal and the bi-material gasket function to form a flangeseal between the flanges of two or more connected components. In apreferred embodiment, the flexor is comprised of a corrugated metalc-ring supported within a recess in the sealing surface of a flange. Themetal c-ring further comprises a surface to which the flexible sealantis juxtaposed and/or attached. The flexible sealant is preferably madeof polycarbon graphite, but may comprise any material capable ofdisplacing with the contraction of the flexor against the connectedflanges to create a flange seal. In addition, other shapes and designsfor the flexor are contemplated herein.

The present invention dynamic flange seal and sealing system isparticularly suited for operation or use with a delayed coking process,and specifically between the various components present within a delayedcoking system, such as a coke drum, a header, a de-header valve, atransition spool, an inlet feed, or a bonnet. Each of these componentstructures are coupled to one another, respectively, via their flangedsegments and require a proper seal therebetween to function properly.Providing the flange connections within a delayed coking process withthe present invention dynamic flange seal and sealing system providesmany advantages, including, but not limited to, improving the integrityof the flange seals, the ability to account for structural andenvironmental changes without breaching the seals, and improving theoverall efficiency of the coking process.

The present invention further features a method for sealing variousflanged components within a high temperature, high pressure environment.This particular method comprises manufacturing flanges with the presentinvention dynamic flange seal and sealing system as described and taughtherein.

The present invention still further features a method for sealingflanged components within a high temperature, high pressure environment.This particular method comprises retro-fitting or modifying existingflanged components, such as a coke drum, transitional spool, feed inlet,and/or de-header valve, with the present invention dynamic flange sealand sealing system as described and taught herein.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the manner in which the above-recited and other advantagesand features of the invention are obtained, a more particulardescription of the invention briefly described above will be rendered byreference to specific embodiments thereof which are illustrated in theappended drawings. Understanding that these drawings depict only typicalembodiments of the invention and are not therefore to be consideredlimiting of its scope, the invention will be described and explainedwith additional specificity and detail through the use of theaccompanying drawings in which:

FIG. 1 illustrates a perspective view of a partial delayed coking systemcomprising a first flanged component, namely a coke drum, coupled to asecond flanged component, namely a transitional spool, with a cutawaysection showing the dynamic flange seal and sealing system as supportedwithin or by the second flanged component, according to one exemplaryembodiment of the present invention;

FIG. 2 illustrates a cross-sectional side view of the first and secondflanged components illustrated in FIG. 1 as coupled and securedtogether, such that the dynamic flange seal and sealing system forms aflange seal between the two, according to one exemplary embodiment ofthe present invention;

FIG. 3 illustrates a semi-detailed cross-sectional view of one segmentor side of the first and second flanged components of FIG. 1 ascomprising the dynamic flange seal and sealing system, according to oneexemplary embodiment of the present invention;

FIG. 4 illustrates a detailed cross-sectional view of the dynamic flangeseal and sealing system as supported within and sealing the flangeconnections of first and second flanged components as coupled or securedtogether, according to one exemplary embodiment of the presentinvention;

FIG. 5 illustrates a detailed cross-sectional view of the iconel bellowsseal and the bi-material gasket elements of the dynamic flange seal andsealing system used to seal the flange connection of two components ascoupled and secured together, according to one exemplary embodiment ofthe present invention; and

FIG. 6 illustrates an alternative embodiment of the dynamic flange sealand sealing system, and particularly the bi-material gasket.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

It will be readily understood that the components of the presentinvention, as generally described and illustrated in the figures herein,could be arranged and designed in a wide variety of differentconfigurations. Thus, the following more detailed description of theembodiments of the system and method of the present invention, andrepresented in FIGS. 1 through 6, is not intended to limit the scope ofthe invention, as claimed, but is merely representative of the presentlypreferred embodiments of the invention.

The presently preferred embodiments of the invention will be bestunderstood by reference to the drawings wherein like parts aredesignated by like numerals throughout.

The present invention describes a method and system for providing aflange to flange seal using a dynamic flange seal and sealing system.With reference to FIG. 1, shown is a perspective view of one exemplaryembodiment of a first flanged component 12 coupled to a second flangedcomponent 20, with a cutaway section showing the dynamic flange seal andsealing system 10 as supported within or by second flanged component 20.Specifically, FIG. 1 illustrates a first component 12 having a flange 14and a sealing surface 16 thereon. First component 12 is connected orcoupled to second component 20 via their respective flanges using one ofseveral means for connecting flanged components together. In oneexemplary embodiment, means for connecting flanged components togethercomprises a bolt connection 22. Other means for connecting flangedcomponents common in the art may be appropriate, each of which arecontemplated herein. However, for the purposes of the presentdiscussion, bolt connection 22 is the preferred means for connectingeach of the flanged components discussed herein. Moreover, it should benoted that the detailed description set forth herein focuses on theconnection and sealing of various flanged components. However,components not in possession of a flange may also comprise or bemodified to comprise the present invention dynamic sealing system ifappropriate. As such, the presence of a flange is not necessary for thepresent invention sealing system to function properly herein. To thecontrary, any metal to metal, metal to plastic, plastic to plastic, etc.may be designed to utilize the present invention sealing system astaught and described herein. As such, the reference to connection offlanged components or a dynamic flanged seal and sealing system is forillustration purposes only and is merely an example of one exemplary,yet preferred, embodiment, and thus should not be considered limiting.

Second component 20 further comprises a flange or second flange 18, alsocomprising a sealing surface 24 (not shown) thereon, that iscomplimentary to and fits with flange 14 of first component 12 to form aconnection of first and second components 12 and 20, respectively. Asillustrated in FIG. 1, first component 12 comprises a coke drum 28coupled to a transitional spool 30 via flanges 14 and 18, respectively,existing thereon. Coke drum 28 and transitional spool 30 are twocomponents utilized in the high temperature, high pressure process orsystem known as delayed coking. Indeed, the design of the presentinvention dynamic flange seal and sealing system 10 lends itselfparticularly well to, or is particularly suited for, use within varioushigh temperature, high pressure environments. In addition, the presentinvention dynamic flange seal and sealing system 10 may be utilized andimplemented in the connections of other components, also possiblyexisting within various high pressure, high temperature environments.For example, in a delayed coking process or system, several componentscomprise flanges and are coupled together using their respectiveflanges. Some of the types of flanged components existing within adelayed coking system are a coke drum, a transitional spool, a header, ade-header valve, an inlet feed, and an upper and lower bonnet. Each ofthese components, or rather each connection between these components,may utilize or have implemented therein the present invention dynamicflange seal and sealing system 10 as taught and described herein. Forexample, transition spool 30 comprises an upper flange 34 and lowerflange 38 supported by spool or sidewall 42. Transitional spool 30 mayattach to coke drum 28 via its upper flange 34 as shown, as well as to ade-header valve (not shown) via its lower flange 38. Within each ofthese flanged connections of transitional spool 30, the presentinvention dynamic flange seal and sealing system 10 may be implementedand utilized to provide an improved and dynamic seal between each ofthese components, and particularly between the flanges of each of thesecomponents. Moreover, although not specifically discussed herein,dynamic flange seal and sealing system 10 may be utilized to sealcomponents together in several different types of environments, otherthan a high pressure, high temperature environment.

As stated, and as can be seen in FIG. 1, first component 12 is coupledto second component 20 via their respective flanges 14 and 18. Inaddition, dynamic flange seal and sealing system 10 is supportedentirely within sealing flange 14 and surface 16 of first component 12,wherein flange 18 of second component 20 is connected to flange 14 offirst component 12, thus creating a flange seal and/or a dynamic flangeseal between the two components. It should be noted herein thatreference to a “first component” and a “second component” is purelyrelative and provided as simple reference points. Essentially, theflanges of two components are made to fit and connect to one another ina complimentary manner, with the flanges providing the means forsecuring two components together. As such, reference to a “firstcomponent” and a “second component” simply provides a way to distinguishbetween two flanged components that are being connected and securedtogether. Moreover, since the flanges of each respective component arecomplimentary to one another, the term “complimentary,” or“complimentary flange,” as discussed herein, is intended to mean ordescribe that particular flange that is being coupled to another flange,whether it be the flange of a first or second component. This definitionis provided for convenience of the reader and to clarify the intendedscope of the present invention, namely to not limit the reference to a“first component” and a “second component” in any way. For instance, ifthe dynamic seal and sealing system is supported within one flange,reference to the “complimentary flange” will mean that particular flangethat is placed over the flange supporting or containing the system,whether it be associated with the first or second component. Inreference to FIG. 1, first component 12 is identified as coke drum 28and second component 20 is identified as transitional spool 30. However,in light of the present discussion, first component 12 may also refer totransitional spool 30 and second component 20 may refer to coke drum 28.In essence, reference to a first and second component, and anyidentification to or association with a particular item is merely forillustration and reference purposes only. Thus, if the flange of firstcomponent 12 is being discussed, the “complimentary flange” will referto the flange of second component 20. Likewise, if the flange of secondcomponent 20 is being discussed, the “complimentary flange” will referto the flange of first component 12.

FIG. 1 further illustrates, in its cut-away portion, dynamic flange sealand sealing system 10 as supported and contained within flange 18 (alsoidentified as upper flange 34) of transitional spool 30. As is shown,dynamic flange seal and sealing system 10 comprises two seals, namely aniconel bellows seal 56 and a bi-material gasket 90 positioned withinflange 18 and within sealing surface 16 between edge 46 and opening 50.In the exemplary embodiment shown in FIG. 1, bi-material gasket 90 ispositioned inside iconel bellows seal 56 in an adjacent or juxtaposedmanner. However, the positioning of each of iconel bellows seal 56 andbi-material gasket 90 with respect to each other and the supportingflange may comprise several arrangements. Indeed, since these sealsfunction independently of the other, each may be positioned or arrayedanywhere along and around the sealing surface of the supporting flangein a circular manner.

As shown, each of iconel bellows seal 56 and bi-material gasket 90extend or are arrayed around the entire rim portion of flange 18, andparticularly sealing surface 16, in a circular manner. Moreover, each oficonel bellows seal 56 and bi-material gasket 90 may be comprised ofsingle, unitary structures, or they may be segmented to comprise aplurality of similar pieces that fit together around flange 18. Ifsegmented, each could comprise varying pieces to accommodate varyingneeds of a particular environment. For instance, if a heavier, morerobust seal is needed in a particular quadrant and not others, providinga more robust segment of seal in this quadrant, yet that would stillfunction with the other segments, would be possible. Various means forconnecting these segments together are contemplated, and are thosecommonly known in the art.

Although FIG. 1 illustrates dynamic flange seal and sealing system 10comprising both iconel bellows seal 56 and bi-material gasket 90, eachof these two components are independent of one another in both functionand form, and can each be used to create an independent flange sealbetween first and second components 12 and 20. However, in theexemplary, yet preferred embodiment shown in FIG. 1, dynamic flange sealand sealing system 10 comprises at least one iconel bellows seal 56 andat least one bi-material gasket 90. Of course, a plurality of each oreither is contemplated herein, depending upon the needs and requirementsof the particular flange connection being sealed.

FIG. 1 also illustrates steam purge inlet 120 as part of a steam purgeand pressure control system. Steam purge inlet 120 comprises an openingin fluid connection with dynamic flange seal and sealing system 10, andparticularly with each of iconel bellows seal 56 and bi-material gasket90. Steam purge inlet 120 is simply a duct for fluid flow, wherein thepressure and flow of fluid within the system can be monitored,controlled, and regulated. Steam purge inlet 120 is preferably linked toan onsite monitoring and control system that allows operators to monitorthe pressure within the flange connection and the sealing system due tothe flow of fluid through the coupled components, as well any leaks inthe flange connection and flange seal(s), and to control the flow offluid within the sealing system. This concept is discussed in greaterdetail below.

FIGS. 2 and 3 illustrate cross-sectional side views of first and secondflanged components 12 and 20, respectively, (shown as coke drum 28 andtransitional spool 30) as coupled and secured together, such thatdynamic flange seal and sealing system 10 forms a flange seal betweenfirst and second flanged components 12 and 20. Specifically, FIGS. 2 and3 illustrate how sealing surface 16 of flange 14 and first component 12fits and collects with complimentary sealing surface 24 of flange 18 andsecond component 20. For example, in a high pressure, high temperatureenvironment, sealing surfaces 16 and 24 are machined to provide a fit orconnection having tight or close tolerances. In addition, FIGS. 2 and 3illustrate the relationship of iconel bellows seal 56 and bi-materialgasket 90 with their respective supporting and securing flange (in thiscase flange 18), as well as with the complimentary flange (in this caseflange 14). As can be seen from the Figures, iconel bellows seal iscontained or supported and secured within a recess in flange 18 andextends from this recess into a similar recess existing within sealingsurface 24 and flange 14. In addition, bi-material gasket is supportedand secured within its own respective recess within flange 18, but onlyextends from this recess up to sealing surface 16 of flange 14. Theserecesses and the securing of iconel bellows seal 56 and bi-materialgasket within their respective recesses is discussed in greater detailbelow with respect to FIGS. 4 and 5.

FIGS. 2 and 3 also illustrate, generally, the positioning andrelationship of steam purge inlet 120 within flange 18 and with respectto dynamic flange seal and sealing system 10, and particularly iconelbellows seal 56. As can be seen, steam purge inlet is part of a steampurge and pressure/fluid control system having one or more passagewaystherein that allow controlled fluid to pass. In the embodiment shown,steam purge system comprises a horizontal passageway 124 in fluidconnection with a vertical passageway 128 that is directly adjacent andin fluid connection with iconel bellows seal 56. The steam purge andfluid/pressure control system is linked to a control module that allowsoperators to monitor the pressure within the entire component system,and particularly between the flange connections and the flange seal(s).The steam purge and fluid/pressure control system also allows operatorsto control the pressure and fluid flow within the same to preserve theintegrity of the created flange seal. For instance, fluid flow betweenthe flange connections and within the flange seal indicates or signalsto operators that there is a leak somewhere in the system. Using thesteam purge system, operators are able to counteract or offset any leaksby controlling the pressure and steam purge within the system, thuscontrolling the flow of fluid in order to counter the leak and maintainthe integrity of the flange seal. Steam purge system also functions tokeep the flanges and the flange connection clean and free from anymaterial or debris. The concept of the steam purge line and system isdiscussed further in relation to FIG. 5.

FIGS. 2-5 further illustrate the beveled portions of flange 14 andflange 18. Flanges 14 and 18 comprise beveled segments to assist in theorientation of flange 14 and flange 18 as they are being connectedtogether. Moreover, iconel bellows seal 56 and bi-material gasket 90 areprotected from damage from the flanges as they are being coupled orconnected together because the flanges are assisted into place due tothe existence of the beveled portions machined therein.

FIGS. 4 and 5 illustrate detailed cross-sectional views of dynamicflange seal and sealing system 10, and particularly iconel bellows seal56 and bi-material gasket 90, as supported within and sealing flanges 14and 18 of first and second flanged components 12 and 20, respectively.With reference to iconel bellows seal 56, FIGS. 4 and 5 specificallyillustrate iconel bellows seal as comprising an external form seal 60and an internal form seal 64 separated by a seal spacer 68. Each ofexternal and internal form seals 60 and 64 function to seal againstsealing surfaces 16 and 24 of flanges 14 and 18, respectively, withinrecesses 70 and 72. External form seal 60 may be referred to as theprimary seal, and internal form seal 64 may be referred to as thesecondary seal. Moreover, bi-material gasket may be referred to as thetertiary seal. In other exemplary embodiments, iconel bellows seal 56may comprise only a single form seal, or one o form seals comprising adifferent shape or configuration. Thus, the present illustratedconfiguration or assembly of iconel bellows seal 56 should not beconsidered limiting in any way, but merely exemplary of an exemplary,preferred, embodiment. Moreover, other structures capable of performingin a similar manner as an iconel bellows seal, namely structures thatare dynamic and that can compensate and adjust for physical variations,but that may be different in form and function than an iconel bellowsseal are contemplated for use herein. The particular focus of iconelbellows seal 56 is not in its particular configuration or form, but inits dynamic capabilities with respect to flanges 14 and 18. As such,other structures or systems capable of performing in a similar manner tocreate a dynamic flange are intended to be within the scope of theinvention as taught and claimed herein.

In one exemplary embodiment, external and internal form seals 60 and 64are biased, or spring-like members that comprise a corrugatedconfiguration and that compliment one another to provide dynamicmovement capabilities within iconel bellows seal 56. Each of internalform seals 60 and 64 are preferably made of high grade steel and areprecision machined to comprise a spring constant, or what issubstantially equivalent to a spring constant, capable of optimallyperforming in the intended environment. Likewise, seal spacer 68 ispreferably made of high grade stainless steel. Of course, other materialcompositions for each of these components are contemplated herein, andmay be utilized as appropriate. External and internal form seals 60 and64 each comprise a plurality of corrugations, depending upon theparticular size of iconel bellows seal 56 needed, that function tocompress upon one another and against sealing surfaces 16 and 24existing within recesses 70 and 72 of flanges 14 and 18, respectively.The relationship between each of these elements creates a flange seal,or rather a dynamic flange seal upon connection and securing of flange14 to flange 18.

As shown, external form seal 60 and internal form seal 64 are supportedor contained within recesses 70 and 72. Each of recesses 70 and 72 maybe pre-manufactured or pre-machined into their respective flange, orthey may be machined on-site as needed, such as to retro-fit an existingflange to comprise an iconel bellows seal. Recess 70 is formed intoflange 14 and accepts or receives at least a portion of iconel bellowsseal 56 therein and at least partially secures iconel bellows seal 56 inits intended position. In the embodiment shown in FIGS. 4 and 5, amajority of iconel bellows seal 56 is supported within recess 70, butthis configuration should not be considered limiting in any way. Recess72 is formed into flange 18 and also accepts or receives at least aportion of iconel bellows seal 56 therein, and also functions to atleast partially secure iconel bellows seal 56 in its intended position.Stated differently, external and internal form seals 60 and 64 arecontained and supported within recess 70 of flange 14 and extend up toand within recess 72 of flange 18. In this configuration, each ofexternal and internal form seals 60 and 64 can compress and expand in asubstantially linear manner (i.e. bi-directional transfer ordisplacement) to adjust to any physical disparity existing withinflanges 14 and 18 as a result of various environmental changes withinthe system as a whole. Thus it can be said that iconel bellows seal 56is a biased, dynamic seal that allows movement within and between theflange connection without affecting the performance of the flange seal.

Being able to compress and expand within its respective securingcounterparts, namely flanges 14 and 18, allows iconel bellows seal 56 tomaintain the integrity of the flange seal it creates. As discussed,external and internal form seals 60 and 64 are compressed to a portionof their total compression ratio upon connection of flanges 14 and 18.This allows iconel bellows seal 56 to comprise what is a biased, dynamicfunction. This function resultantly allows iconel bellows seal to adjustor adapt or modulate to varying temperatures, pressures, and/orcompression forces existing or potentially existing between the flangesand the flange seal that create physical disparities within flanges 14and 18, in order to preserve the integrity of the flange seal created byiconel bellows seal 56 and dynamic flange seal and sealing system 10.Indeed, often existing within flange connections of various componentsand their respective flange seals, especially within high temperature,high pressure systems, is a certain amount of structural differentialscaused by the extreme pressure and temperature variations experienced.Such variations tend to induce a significant amount of physical stressin these connected components that leads to inflection or disparitywithin them, which disparity can subsequently induce a breach in theflange seal, thus creating leaks and inefficiency within the overallsystem. As such, flanges 14 and 18, while securely coupled to oneanother, may undergo significant stresses that cause their physicalstructures to become tweaked. For instance, the sealing surfaces ofthese two components may not be as tightly sealed together as possibleas a result in the loss of the tight tolerances between the two asinitially present. To account for any physical disparities or potentialphysical disparities, as a result of whatever manufacturing process istaking place, iconel bellows seal 56 comprises the biasing or dynamicelement discussed above. Indeed, as flange 14 is connected to andsecured to flange 18, iconel bellows seal 56, and particularly internaland external form seals 60 and 64, is/are at least partially compressedwithin recess 70 and recess 72, respectively, such that external formseal 60 and internal form seal 64 are allowed to compress and expand ina linear manner to account for and adjust to any physical disparityexisting between flange 14 and flange 18. Thus, the dynamic relationshipof iconel bellows seal 56 to flanges 14 and 18 functions to preserve theintegrity of the flange seal created by iconel bellows seal 56.

In the embodiment shown in FIGS. 4 and 5, iconel bellows seal 56 isoperational within a delayed coking system, wherein flange 14 is theflange of a coke drum and flange 18 is the flange of a header, de-headervalve, or transitional spool. In this environment, approximately 450p.s.i. is placed upon iconel bellows seal upon the connection andsecuring of flanges 14 and 18 together.

Iconel bellows seal 56 is preferably secured in a semi-sealed state. Ofcourse, the present invention contemplates a complete seal, but this isnot preferred for the reasons provided herein. With reference to FIGS. 4and 5, external and internal form seals 60 and 64 are contained andsupported within recesses 70 and 72 machined from flanges 14 and 18. Theends of internal form seals 60 and 64, namely toes 76, 80, 84, and 88,are the primary structural elements of form seals 60 and 64 that contactsealing surfaces 16 and 24 within recesses 70 and 72. In order to createa semi-sealed configuration, in one exemplary embodiment, only some oftoes 76, 80, 84, and 88 are sealed to their respective flangecounterparts. As mentioned above, fluid is allowed to travel or passthrough flanges 14 and 18 and the flange seal created by dynamic flangeseal and sealing system 10 sealing these two structures together, butonly under controlled conditions. Indeed, it is preferable to be able tocontrol the fluid and pressure within the overall system to counteractor offset any leaks and to prevent unwanted materials from entering intothe flange seal. Indeed, if iconel bellows seal were completely closedoff to fluid flow, steam purge system could not be used to monitor andcontrol the flow of fluid between the flanges and within the flangeseal. Thus, to allow operators this control, and to preserve theintegrity of the flange seal and the life of the components orstructures involved, iconel bellows seal 56 is only partially sealed todirect the flow in a certain direction and through specific, identifiedpassageways. In the embodiment shown in FIGS. 4 and 5, iconel bellowsseal 56 comprises toes 76, 80, and 88 that are sealed to theirrespective flange counterparts. Toe 84 is left unsealed to specificallydirect and allow fluid flow through the space between toe 84 and sealingsurface 24 of flange 14. As such, fluid flow is cut-off from flowingthrough iconel bellows seal 56 by leaving toe 84 unsealed, exceptthrough the passageway created between toe 84 and the portion of sealingsurface directly opposite toe 84.

In one exemplary embodiment, sealing toes 76, 80, and 88 to theirrespective flange counterparts involves placing a specificallyidentified amount of silver within recesses 70 and 72 prior to insertingtoes 76, 80, and 88 and at the precise location each of these toescontacts flanges 14 and 18 within recesses 70 and 72. The sealing oftoes 76, 80, and 88 takes place upon securing flanges 14 and 18 togetherand by initiating a manufacturing process, such as a delayed cokingprocess. The extreme heat and pressure existing within the system as aresult of the coking process functions to meld or bond the silver toeach of toes 76, 80, and 88, as well as to flanges 14 and 18, thuscreating a seal, or a silver seal, therebetween. Other types of sealscommon in the art and capable of providing a seal at each toe arecontemplated herein and may be utilized to provide the semi-sealedarrangement described herein. The particular type of seal will largelydepend upon the environment in which the seal will be used.

The present invention dynamic flange seal and sealing system furthercomprises a bi-material gasket 90 positioned or arrayed in a circularmanner around an opening or rim portion of flange 18 (the supportingflange) and that functions to create a flange seal. In the exemplaryembodiment shown in FIGS. 4 and 5, bi-material gasket 90 is positionedinside iconel bellows seal 56 around sealing surface 24 of flange 18 inan adjacent or juxtaposed manner. However, the relative positioning ofeach of iconel bellows seal 56 and bi-material gasket 90 with respect toeach other and the supporting flange may comprise several arrangements.Since these seals function independently of the other, as discussedabove, each may be positioned at any location along and around thesealing surface of the supporting flange. Bi-material gasket 90comprises flexor 94 and a flexible sealant 102 united or coupled withflexor 94. In one exemplary embodiment, flexor 94 comprises a corrugatedmetal/graphite gasket in the form of a metal c-ring having a flexiblesealant 102, in the form of a high density graphite packing, bonded toinside surface 98 of flexor 94 and extending therefrom. Bi-materialgasket 90 functions to provide a flange seal upon connection andsecuring of flange 14 to flange 18. Connecting flange 14 causes sealingsurface 16 to contact flexor 94 and apply a downward, linear force toflexor 94. This force applied to flexor 94 causes it to flex orcontract, thus displacing all or part of flexible sealant 102 away fromflexor 94 and toward sealing surfaces 16 and 24 of flanges 14 and 18,respectively, wherein a flange seal is created. Flexible sealant 102comprises several sealing faces, namely sealing faces 106, 110, and 114,that contact the parts of sealing surface 16 existing within recess 86,as well as sealing surface 24 to create a seal between the respectiveflange components. From FIGS. 4 and 5 it can be seen that flexor 94 isdesigned to extend above sealing surface 24 only a small amount. Thisamount may vary from design to design, but should be sufficient so thatthe complimentary flange being connected to the flange supporting flexor94 contacts the top of flexor 94 enough to apply a force thereon andcompress flexor 94 without interfering with the tight toleranceconnection of flanges 14 and 18. Once compressed, flexible sealant 102is forced to displace and seal against sealing surfaces 16 and 24. Inthe embodiment shown in FIGS. 4 and 5, bi-material gasket 90 isoperational within a delayed coking process, wherein the flexorcomprises a flex factor pre-designed or pre-identified for use withinthis particular type of system. The flex factor of flexor 94 is pertainsto the compression force needed to flex or compress flexor 94 asufficient amount to cause flexible sealant 102 to volumetricallydisplace. The flex factor also dictates the amount of proportionalvolumetric displacement of flexible sealant 102, the force of flexiblesealant 10 against flanges 14 and 18, and the strength of the flangeseal between these two components. As such, different flex factors canbe built into different flexors, depending upon the limitations andconstraints of the particular intended system the flexors will be usedwithin. In the exemplary embodiment shown, flexor 94 comprises a flexfactor that is set to cause flexor 94 to activate or operate properlyupon compression reaching 2500 p.s.i. At this compression, flexor 94 isproperly compressed or contracted and flexible sealant 102 is properlydisplaced and sealed against flanges 14 and 18 to create a flange seal.Thus, any increase in pressure will result in a stronger flange seal,and any decrease in pressure will result in possible breach of theflange seal where leaking may occur. Maintaining a proper amount orrange of pressure upon flexor 94 can be accomplished using steam purgesystem 120, as discussed herein.

Another force acting upon flexor 94 to cause it to contract and displaceflexible sealant 102 is the internal pressure within the system. Flexor94 comprises a first toe 96 and a second toe 100. First and second toes96 and 100 are preferably oriented in a downward manner, as shown, inorder to respond favorably to the extreme pressure that often existsbetween connected flanges and within high pressure, high temperaturemanufacturing processes. As the pressure within the system rises, firstand second toes 96 and 100 are further forced inward as a result of thepressure in the system, and particularly the steam purge line, thuscontributing to the creation and maintenance of the flange sealinitially created by the displaced flexible sealant 102.

Bi-material gasket 90 is supported within recess 86 of flange 18. InFIGS. 4 and 5, bi-material gasket 90 is installed inside and adjacent orjuxtaposed to iconel bellows seal 56. As mentioned above, bi-materialgasket 90 may serve as a tertiary seal along with the primary andsecondary seals (external and internal form seals, respectively) oficonel bellows seal 56. However, as explained above, each of thesecomponents are independent of one another, but may be used to complimentone another to create a flange seal. Recess 86 is machined out ofsealing surface 24 of flange 18, thus comprising a portion of sealingsurface 24 within recess 86 to which flexible sealant 102 may sealagainst. Machining recess 86 to receive a bi-material gasket can be donewith newly manufactured flanges, or the machining of recess 86 can bedone to existing flanges on-site to modify them to be able to supportand utilize bi-material gasket 90.

FIG. 6 illustrates another exemplary embodiment of dynamic flange sealand sealing system 10. Specifically, FIG. 6 illustrates bi-materialgasket 90 as comprising an alternative configuration and makeup. In thisparticular embodiment, bi-material gasket 90 comprises a flexor in theform of a corrugated iconel form seal in connection with a flexiblebraided graphite sealant. The flexible braided graphite sealant iscomprised of a flexible jacket of expanded exfoliated grafoil. Unlikethe previous embodiment in which flexible sealant 120 was bonded toinside surface 98 of flexor 94, the flexible sealant 164 illustrated inthe embodiment shown in FIG. 6 does not bond or adhere to flexor 160.Rather, flexible sealant 164 is positioned adjacent flexor 160 and is atleast partially extruded into the corrugated segments of flexor 160 uponcompression of flexor 160 by flange 18. Despite its differences instructure, flexor 160 and associated flexible sealant 164 each functionsimilarly to flexor 94 and flexible sealant 120 as illustrated in FIGS.1-5 and discussed above, namely in that they function together to createa flange seal between flanges 14 and 18. Specifically, as flange 14 isconnected and secured to flange 18 containing bi-material gasket 90 (andiconel bellows seal 56, as shown), flange 14 induces or applies a forceto flexor 160, which causes it to compress. In the embodiment shown inFIG. 6, flexible sealant is caused to displace approximately 18%.Subsequently, the compression of flexor 160 causes flexible sealant todisplace and seal against the sealing surfaces of flanges 14 and 18. Assuch, it can be said that bi-material gasket, in any form, is a flexibleseal.

With reference to FIGS. 1-6, there the present invention furthercomprises a system for controlling the pressure and flow of fluid withinthe system and within the flange seal. Once connected, and once dynamicseal and sealing system 10 is functional, an identified andpre-determined fluid flow pattern exists within the connectedcomponents. This flow pattern is indicated or illustrated in FIG. 5 bythe arrows. Fluid flows within flow channel 150, through duct 154, andgenerally along the lines indicated by the arrows, which indicate thatfluid flows between sealing surfaces 16 and 24, as well as through thevarious flange seals created by dynamic flange seal and sealing system10. As stated above, a steam purge inlet or system 120 is utilized tocontrol the pressure within the system, as well as to provide controlledfluid flow. Duct 154 comprises a beveled edge for the purpose preventingpinching upon connection of flanges 14 ands 18, as well as forfacilitating the removal of various materials or other debris as theflanged components are separated and re-connected. Providing a bevelededge in at least one of the vertical edges of duct 150 allows debris andmaterial to be more easily released from the sides of duct 154.

Fluid flow is provided or allowed for several reasons. First, in theeven one of the flange seals begins to deteriorate and fail, pressurecan be increased to counteract and offset any fluid, material, or debriswanting to pass therethrough. Second, seal integrity can be maintainedand controlled to a certain extent. Third, the sealing surfaces andflange connections can be kept clean and free of debris or othermaterials because the pressure can be increased through steam purgeinlet 120, thus re-directing the flow of fluid and materials back towardtheir original location. Other advantages not specifically recitedherein will be apparent to one ordinarily skilled in the art.

The present invention further features a method for sealing flangedcomponents within a high temperature, high pressure environment. Themethod comprises the steps of: (a) obtaining a first component having aflange; (b) obtaining a second component having a flange, each of theflanges being complimentary to each other; (c) providing a dynamicflange sealing system within at least one of the flanges of the firstand second components; and (d) securing the first component to thesecond component via their respective flanges, wherein the step ofsecuring causes the flexor to contract or compress, and wherein theflexible sealant displaces and seals against the respective sealingsurfaces of the flanges of the first and second components, relative tothe amount the said flexor contracts or is compressed, the dynamicflange sealing system providing a flange seal between the first andsecond components.

The dynamic flange sealing system comprises an iconel bellows sealsupported in one of the flanges of the first and second components andextends to and is received by the complimentary flange upon theirconnection, wherein the iconel bellows seal provides a dynamic sealbetween the first and second components; and a bi-material gasketsupported within at least one of the flanges of either the first orsecond components, the bi-material gasket comprises a flexor and aflexible sealant partially connected to the flexor.

The present invention further features a method for modifying anexisting flange connection to enhance the seal between a first andsecond flange. The method comprises the steps of: (a) obtaining a firstcomponent having a flange and at least one sealing surface thereon; (b)obtaining a second component having a flange and at least one sealingsurface thereon, each of the flanges being complimentary to one another;(c) retro-fitting at least one of the flanges of the first and secondcomponents with a dynamic flange sealing system supported within itsrespective sealing surface; and (d) securing the first component to thesecond component via their respective flanges, thus causing the flexorto contract, wherein the flexible sealant displaces and seals againstrespective sealing surfaces on the flanges of the first and secondcomponents, relative to the amount the flexor contracts, the dynamicflange sealing system providing a flange seal between the first andsecond components.

The dynamic flange seal and sealing system comprises a bi-materialgasket supported within one of the flanges of the first and secondcomponents, wherein the bi-material gasket comprises a flexor and aflexible sealant partially connected to the flexor. The dynamic flangesealing system may further comprise an iconel bellows seal supported inone of the flanges of the first and second components and extending toand received by the complimentary flange upon their connection, theiconel bellows seal providing a dynamic seal between the first andsecond components. The step of retro-fitting comprises cutting a recessin said sealing surface to support said bi-material gasket.

The present invention dynamic flange seal and sealing system providesmany advantages over prior art seals or sealing systems. First, lesscompression or force between the connected flanges is needed to maintainthe integrity of the flange seal. This functions to preserve the life ofthe connection means used to connect and secure the two componentstogether. For example, in systems using bolt connections to couple andsecure two flanges together, such as within a high pressure, hightemperature delayed coking environment, use of the present inventiondynamic flange seal and sealing system requires the bolt connections toonly be tightened or torqued to around sixty percent (60%) of theiryield strength in order to maintain the integrity of the flange seal.This remaining or reserve yield strength within the bolts provides asignificant amount of additional torque and subsequent compressionbetween flanges, if needed. In similar systems using prior art sealingdesigns, the bolt connections are required to be tightened, or aretorqued, to around ninety percent (90%) of their yield strength.Although this high stress level is required in order to maintain theseal between the connected flanges of the various components, it allowsfor very little additional torquing in each bolt that can be utilized ifconditions require. Indeed, using prior art designs, if there is a leakin the flange seal between the connected flanges, the bolts can only betightened a slight amount before they reach their full yield strengthand shear, thus requiring them to be replaced. Moreover, continuous, orrather cyclical, tightening of bolt connections to this level of stressincreases their rate of fatigue, thus decreasing their durability andoverall life. Such is not the case with use of the present inventionseal and sealing system.

Second, flange connections can maintain the same sealing materialthroughout several cycles of various manufacturing processes.

Third, existing flange connections can be modified or retro-fit onsiteto include the dynamic seal and sealing system of the present invention.This is advantageous for several reasons, including, components are notrequired to be replaced, there is minimal downtime while retrofittingthe flanges, the lifespan of various means for connecting and securingflanged components together (e.g. bolt connections) is increased, andgreater flange seals are achieved that prevent leaks. Each of thesefunctions to improve efficiency and reduce overall operating costs.

Other advantages of the present invention, not specifically recitedherein, but that are obvious to one of ordinary skill in the art arecontemplated herein. As such, those specific examples set forth aboveare not to be considered limiting in any way.

The present invention may be embodied in other specific forms withoutdeparting from its spirit or essential characteristics. The describedembodiments are to be considered in all respects only as illustrativeand not restrictive. The scope of the invention is, therefore, indicatedby the appended claims, rather than by the foregoing description. Allchanges which come within the meaning and range of equivalency of theclaims are to be embraced within their scope.

1. A delayed coking system comprising: a coke drum having at least oneflange and respective sealing surfaces thereon; a component member alsohaving a flange and a sealing surface thereon that are complimentary tosaid flange and said sealing surface of said coke drum, said coke drumand said component member connecting together via their respectiveflanges within said delayed coking system; and a high temperature, highpressure dynamic flange sealing system that seals said component memberto said coke drum, said dynamic flange sealing system comprising: abi-material gasket supported within a recess of said sealing surface ofsaid flange of at least one of said coke drum and said component member,said bi-material gasket comprising a flexor and a flexible sealantattached thereto, wherein upon said connection of said flange of saidcoke drum and said flange of said component member, said flexor and saidflexible sealant contact said sealing surface of said complimentaryflange, and wherein said flexor is caused to contract relative to theforce exerted and applied thereon, said force resulting from thepressure generated within said flanges upon connection, said flexorresultantly forcing said flexible sealant to displace against saidsealing surfaces and form a seal and a flange seal between said flangesof said coke drum and said component member.
 2. The delayed cokingsystem of claim 1, further comprising an iconel bellows seal containedand supported within a recess formed in said sealing surface of saidflange of at least one of said component member and said coke drum andextending into a recess in said sealing surface of said complimentaryflange upon connection of said flanges, said iconel bellows sealproviding a biased, dynamic seal that adjusts to structural variationswhile maintaining the integrity of said seal, said iconel bellows sealindependently forms a flange seal and also compliments said bi-materialgasket to form said flange seal, if desired.
 3. The delayed cokingsystem of claim 1, further comprising a steam purge system designed toregulate pressure and control fluid flow within said dynamic flangesealing system and between said flanges of said coke drum and saidcomponent member, in order to preserve the integrity of said flangeseal, said steam purge system comprising a plurality of passageways inwhich fluid and material and debris may be controlled to pass.
 4. Thedelayed coking system of claim 2, wherein said iconel bellows sealcomprises at least one of an internal form seal and an external formseal, and a seal spacer.
 5. The delayed coking system of claim 1,wherein said flexor is comprised of a corrugated metal structure.
 6. Thedelayed coking system of claim 1, wherein said flexor is comprised of ametal c-ring.
 7. The delayed coking system of claim 1, wherein saidflexor comprises a flex factor that is appropriately respondent to thecompression force existing between said flanges when connected andapplied to said flexor, said flex factor dictating the amount ofproportional displacement of said flexible sealant, the force of saidsealant against said flanges, and the strength of said seal between saidflanges.
 8. The delayed coking system of claim 1, wherein said flexiblesealant is comprised of polycarbon graphite adhered to at least aportion of and extending from said flexor.
 9. The delayed coking systemof claim 1, wherein said flexible sealant is comprised of a flexiblebraided graphite sealant that is comprised of a flexible jacket ofexpanded exfoliated grafoil.
 10. The delayed coking system of claim 2,wherein said iconel bellows seal is supported within said recess in asemi-sealed arrangement to allow fluid flow therethrough and betweensaid flanges.
 11. The delayed coking system of claim 10, wherein saidiconel bellows seal is silver sealed in a first, second, and thirdlocation, thus providing said semi-sealed arrangement and allowing fluidflow therethrough and between said flanges.
 12. The delayed cokingsystem of claim 1, wherein said bi-material gasket is segmented aroundsaid sealing surface of said first flange.
 13. The delayed coking systemof claim 2, wherein said iconel bellows seal is segmented around saidsealing surfaces of said first and second flanges.
 14. The delayedcoking system of claim 1, wherein said component member is selected fromthe group consisting of a transitional spool, a de-header valve, aheader, an inlet feed, a bonnet, and any other similar componentutilized and existing within a high temperature, high pressureenvironment.
 15. The delayed coking system of claim 1, wherein saidflexor comprises first and second toes at opposing ends of said flexorand that function to direct the displacement of said flexible sealantaway from said flexor and toward said flanges.
 16. The delayed cokingsystem of claim 15, wherein said toes extend upward as they extendoutward, thus allowing pressure within said system to further compresssaid flexor and contribute to the displacement of said flexible sealantand said flange seal.
 17. The delayed coking system of claim 1, furthercomprising means for connecting said coke drum to said component, saidmeans for connecting comprising a plurality of bolt connections, whereinsaid flange seal is created when said bolt connections are tightened tobetween about 50 and 70 percent of their yield strength.
 18. The delayedcoking system of claim 2, wherein said iconel bellows seal and saidbi-material gasket function independently of one another to createindividual flange seals.
 19. The delayed coking system of claim 2,wherein said iconel bellows seal and said bi-material gasket worktogether to form said flange seal.
 20. The delayed coking system ofclaim 1, wherein said coke drum and said component comprisecomplimentary beveled segments that function to orient the two togetherupon connection and that protects said dynamic flange scaling system.21. The delayed coking system of claim 1, wherein said second componentfurther comprises a beveled duct adjacent said dynamic flange sealingsystem, said beveled duct allows material and fluid to flow therethroughand to clean any material and debris therein upon connection andseparation of said coke drum and said component.